3900 MPV ™ 3900 (SRV-1/Q4.04) 3900.1 Consolidated ® offers a unique pilot valve design that combines top performance, capabilities and features within an economical, modular assembly. Consolidated has accomplished this feat by successfully designing an optimized safety “system” that offers versatility of application, yet provides cost effective standardization. New Features This product update of Consolidated’s 3900 POSRV covers the following changes and/or additions: • Bonnet is now standard for all pilot valves. • 39MV22 (751 – 3750 psig) – replaces the 39MV37 The 39MV22 modulator is built internally into the pilot valve. This design reduces product cost, improves modulating performance and increases energized seal life. • 39MV72 (3751 – 6250 psig) Based on the same design as the 39MV22, this pilot allows Consolidated to expand its product offering into the 2500# Class pressure range. • 3900 POSRV (main valve) metal seat option The metal seat option incorporates proven technology from the 1900 SRV metal seat design. With the addition of the 2900 POSRV heat exchanger, the metal seat option will increase the temperature range for the 3900 POSRV product line to -320 °F to 650 °F. • Pilot Gag – prevents the pilot operated relief valve from opening while equipment is being subjected to an operational hydrostatic test. Please refer to the following tables for Pressure – Temperature Ratings, Dimensions and Weights, and capacity charts for air, water and steam. 3900 Pilot Operated Relief Valve 3900
66
Embed
3900 Pilot Operated Relief Valve - VAPORASKIA AG...• ISO 4126-4 • API 520, API 526, and API 527 • ANSI B16.34 3900 MPV Standard Features 39PV Pop Pilot 39MV Modulating Pilot
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
3900 MPV™
3900 (SRV-1/Q4.04)3900.1
Consolidated® offers a unique pilot valve design that combines top performance, capabilities and features within an economical, modular assembly. Consolidated has accomplished this feat by successfully designing an optimized safety “system” that offers versatility of application, yet provides cost effective standardization.
New Features
This product update of Consolidated’s 3900 POSRV covers the following changes and/or additions:
• Bonnet is now standard for all pilot valves.
• 39MV22 (751 – 3750 psig) – replaces the 39MV37
The 39MV22 modulator is built internally into the pilot valve. This design reduces product cost, improves modulating performance and
increases energized seal life.
• 39MV72 (3751 – 6250 psig)
Based on the same design as the 39MV22, this pilot allows Consolidated to expand its product offering into the 2500# Class pressure
range.
• 3900 POSRV (main valve) metal seat option
The metal seat option incorporates proven technology from the 1900 SRV metal seat design. With the addition of the 2900 POSRV
heat exchanger, the metal seat option will increase the temperature range for the 3900 POSRV product line to -320 °F to 650 °F.
• Pilot Gag – prevents the pilot operated relief valve from opening while equipment is being subjected
to an operational hydrostatic test.
Please refer to the following tables for Pressure – Temperature Ratings, Dimensions and Weights,
and capacity charts for air, water and steam.
3900 Pilot Operated Relief Valve
3900
3900 MPV™
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q4.04)3900.2
3918 Series Type 39PV & 39MV - Dimensions & Weights2500# Inlet, Single Outlet, Standard Bore
• ASME B & PVC, Section VIII, Division I • NACE MR0175• D.O.T. Subchapter D Parts 192 and 195 • ISO 4126-4• API 520, API 526, and API 527 • ANSI B16.34
3900 MPV
Standard Features 39PV Pop Pilot 39MV Modulating Pilot
Convertible valve action To Modulating To Pop Full Lift at Set Pressure 110% of Set Pressure Adjustable blowdown 2% to 7% 2% to 7% Leak tight seats at % of set pressure 95% to 98% 96% to 99% Main valve seat tight to set point Yes Yes Field test connection Yes Yes Gas, liquid and steam service (ASME B & PVC, Section VIII) Yes Yes Non-Flowing pilot Yes Yes Pilot construction entirely stainless steel Yes Yes Set point repeatability to within +/-2% Yes Yes 100 micron filter protects pilot Yes Yes Designed for ease of maintenance Yes Yes
3900 MPV™
Features / Scope of Design
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.2
3900 Flanged Series Overview
CONSOLIDATED, world leader in providing safety and safety relief valve solutions, offers the new CONSOLIDATED Modular Pilot Valve (MPV), a pilot operated safety relief valve. The 39MPV is a unique pilot valve design; combining top performance, capabilities and features within an economical, modular assembly. CONSOLIDATED has accomplished this feat by successfully designing an optimized safety “system” that offers versatility of application, yet provides cost effective standardization. Proven concepts and principles refined from over 100 years of successful design and application experience have been integrated into the CONSOLIDATED MPV, resulting in the production of a new and highly reliable pilot operated safety relief valve which is easy to operate and maintain.Global concern for the environment continues to expand. The need to improve the operational efficiency of all types of process plants is worldwide. The need for relief valves that provide bubble tight operation and precise opening and closing pressures is increasing due to this trend. CONSOLIDATED Pilot Operated Safety Relief Valves offer high quality production products, performance characteristics and features that are consistent with today’s industry demands.The combining of our pilots into one unique design provides major benefits. This new design pilot valve is suitable for incompressible and compressible applications including steam. Adapting to various applications will require only the appropriate selection of soft goods and options to meet the service conditions.
VersatilityThe CONSOLIDATED MPV is the FIRST true modular pilot operated safety relief valve design that combines pop and modulating functions within a single
assembly suitable for incompressible and compressible fluids including steam.CONSOLIDATED MPV pilot operated safety relief valves meet API 526 requirements. For higher capacity requirements, full bore sizes are available up to 69.94 sq. inches, some with dual outlets. Available pressure class ratings are ANSI Class 150 to Class 1500.
Total ServiceThe MPV is manufactured by CONSOLIDATED, a TOTAL solutions provider of pressure relief products offering unmatched application expertise and after sales support on a world wide basis.
IntroductionCONSOLIDATED 39MPV Series Pilot Operated Safety Relief Valves are designed to provide reliable protection for a broad range of pressurized systems applications. The operating characteristics and design of pilot actuated relief valves differ significantly from spring loaded pressure relief valves. It is extremely important that the user recognizes the merits of each design and select valves based on a valid comparison. The CONSOLIDATED pressure relief valve designs meet the needs of most applications found in the markets we currently serve.CONSOLIDATED strives to provide the best available information, data and assistance to its customers in the selection and application of our products. It is impractical, however, for CONSOLIDATED personnel to be trained in all systems and processes in which our products might be used. Ultimate responsibility remains with the customer as the process owner or designer.
Product types covered in subsequent pages are noted below.
The CONSOLIDATED 3900 series pilot operated safety relief valve is supplied with a non-flowing pilot valve. This single pilot design is suitable for both incompressible and compressible applications and performs equally well on liquid, vapor or two-phase flow services. The set pressure will not require adjustment if the service condition changes.
Because of its modular design, the 39PV (pop pilot) can be converted to a 39MV (modulator pilot). This makes the CONSOLIDATED 39PV and 39MV pilot valve the most versatile pilot valve on the market.
Product Type 3900 3900 3900 3900
Pilot Type 39PV 39MV 39PVSS 39MVSS
Service gas/liquid gas/liquid steam steam
Description pop action - non flowing modulating - non flowing pop action - non flowing modulating - non flowing
3900 MPV™
Features / Scope of Design
3900 (SRV-1/Q2.02)3900.3
3900 Flanged Series Overview
NOTES: 1 The above table is general in nature and is to be used as a guideline only. 2 Refer to the “Pressure/Temperature” Chart on page 3900.55 for actual pressure limits at a given temperature by pressure class and materials of construction. 3 Refer to the “Soft Goods Selection” Chart on page 3900.9 for material selection for a given pressure, temperature, fluid type, durometer hardness, and orifice size.
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.4
3900 Flanged Series Overview
NOTES: * Review the outlet flange rating and review the capacity correction factor. ** A cold differential test pressure (CDTP) must be applied for a 39PV with constant back
pressure over 15% of set pressure. *** Contact factory for permissible backpressure limits when pilot vent is piped to valve outlet.
Options
YesYesYesYesYesYesYesYesYesYesYesYes
YesYesYesYesYesYesYesYesYesYesYesYes
Manual Blowdown Valve (standard for steam service)Backflow PreventerRemote SensingRemote Pilot MountingOptional Sensing LineDual PilotsDual FiltersPressure Differential SwitchBonnet (vented)Metal Spring Cover (encloses yoke & spring)High Capacity Line Filter (with flush valve)Remote Actuated Blowdown
Applications
Type Pop Action - Non Flowing Yes No Modulating - Non Flowing No Yes
Media Air, Gas Yes Yes Vapor Yes Yes Dirty Vapor (filter required) Yes Yes Steam Yes Yes Liquid Yes Yes
Operational Conditions Icing Yes Yes Pulsations Yes Yes Reduces Water Hammer (when valve closes) Yes Yes Operational Performance Pressure Range: 15 - 3750 (Gas/Liquid/Steam) Yes Yes 15 - 750 (Steam) Yes Yes Blowdown: 3% Yes 5% Yes Main Valve Seat Tightness: Bubble tight at 99% of set pressure Yes Yes
* Back Pressure (vent piped to main valve outlet): Variable - % of Set Pressure 15% 65% Constant - % of Set Pressure ** 65%
* Back Pressure (with pilot vented to atmosphere): Variable - % of Set Pressure 65% 65% Constant - % of Set Pressure 65% 65%
* Back Pressure (with pilot vented to body bowl): Variable - % of Set Pressure 15% 65% Constant - % of Set Pressure 65% 65%
* Back Pressure (vent not piped to main valve outlet): *** ***
The main valve has six basic components. Assembly and disassembly are accomplished through top entry. This means that as long as there is no pressure in the system, routine maintenance, such as replacement of O-Rings and seals, may be done with the valve in place, virtually eliminating the need for cranes and additional manpower.
BaseThe base is cast with integral flanges. It forms the main structure and is a pressure boundary component since it will be exposed to process media. To ensure integrity and reliability, all base castings are produced to the latest addition to the ASME Boiler & Pressure Vessel Codes. The standard materials are Grade WCC carbon steel, and Grade CF8M 316 stainless steel. Other materials such as Monel, Hastelloy, and additional code-approved materials are available to satisfy more demanding requirements. The discharge side of the body is drilled and tapped for pilot venting. If the pilot is vented to the atmosphere, a pipe plug is installed to secure this area.
NozzleThe 316 stainless steel nozzle performs two functions: First, it forms the lower sealing surface. Second, the nozzle controls the capacity. The orifice is machined into the nozzle ensuring that rated flow capacities will be obtained should an overpressure condition occur. The nozzle is threaded or bolted into the body and sealed with an O-Ring. By threading or bolting the nozzle it may be removed easily for repair or replacement.
GuideThis one piece guide of 316 stainless steel ensures true alignment of the disc and nozzle for positive, bubble tight sealing. The heavy guide construction is designed to prevent warping or egging when the valve is in service.
DiscThe disc is 316 stainless steel. An O-Ring (part 10) is used for isolating the dome chamber when used on air, gas or liquid service. A spring energized Teflon® seal (part 17) is used on the top side of the disc for steam service. A graphite impregnated Teflon® guide ring (or rings) (part 16) provides a low coefficient of friction for the guiding function between the disc and guide. An O-Ring seat (part 12) performs the primary sealing function for the disc to ensure bubble tightness. The metal-to-metal stop for the seat allows the valve to still function, even if the O-Ring is damaged or destroyed.Two unique features distinguish the CONSOLIDATED O-Ring seat seal safety relief valve from any other design. These are the 50 degree metal-to-metal load bearing seats and the slotted O-Ring retainer.
There are three essentials to a tighter and more secure seal:
1. Concentric Alignment The nozzle bore and O-Ring retainer are both machined to an
angle of 50 degrees. This ensures that as the valve disc opens and closes the O-Ring is aligned concentrically against the lip of the nozzle. Close tolerance between the nozzle and the body also helps to ensure a tight seal when the valve is closed.
2. Maximum Sealing Force On the back side of the O-Ring retainer, there are two small
slots. When the valve is closed; process media enters between the machined seat of the nozzle and the O-Ring retainer, and proceeds up the slots behind the O-Ring. This pressure forces the O-Ring against the lip of the nozzle and the curved recess of the disc. As the pressure within the valve rises to set point, the O-Ring is pressed tightly against the nozzle to maintain maximum sealing force until valve set pressure is reached.
3. O-Ring Retention When the valve opens, the pressure behind the O-Ring escapes from
these same two slots on the O-Ring retainer. This prevents the O-Ring from being ejected. Additionally, the O-Ring encapsulating retainer prevents the O-Ring from being ejected by the high velocity, low pressure discharge inside the upper valve body.
Cover PlateThe cover plate secures the guide and seals the main body. Each cover plate is drilled and tapped for eye bolts which are used for ease of assembly or disassembly of the main valve and for handling the assembled valve.
Sensing TubeThe sensing tube is machined from 316 stainless hex bar stock and is threaded into the main body at a location below the nozzle. The sensing tube picks up media pressure and feeds this pressure through the sensing line to the pilot. To ensure proper orientation, one side of the hex is marked UP. This marking is to be oriented upward when the valve is sitting on its inlet flange. The pilot valve can also be installed in applications where remote sensing of pressure is used to actuate the pilot. In this case, the sensing tube is installed at the desired sensing location and connected by the sensing line to the pilot. The sensing tube port in the main valve is then sealed with a pipe plug.
OtherThe remaining parts: studs, nuts, spring, nameplate, and lead seal complete the assembly of the main valve. A wire and lead seal are affixed to the pilot to protect the pilot valve adjustments.
3900 Materials Overview
3900 MPV™
Main Valve Materials
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.8
NOTES: 1 Disc O-Ring (10) is not required for steam service. 2 Disc Seal (17) is provided for steam service and when O-Ring Seat (12) is Teflon®. 3 Main base assemblies can be provided in special materials. Contact the factor for availability. * Not shown.
Main Valve Materials3
Part Standard Material Entirely Stainless (S4) NACE (SG1) - Internal Service Only
Soft Goods selection for liquid and gas service is accomplished as follows:
A) Material Selection - Refer to Technical Information Section, O-Ring Selection beginning
on page TI.22. - Locate valve fluid and read the applicable O-Ring material. - For fluids not listed, the customer must specify the O-Ring material.
B) Main Valve Pressure Limits - Refer to Table 1 on page 3900.10. - Locate the valve orifice and select the durometer for the required
set pressure.
NOTES: 1 Disc O-Ring (10) or Disc Upper O-Ring (17) shall be one of the same material and durometer as that selected for the O-Ring Seat (12). 2 When Teflon® is selected for O-Ring Seat (12) the Disc Seal (17) shall be a Teflon® energized seal. 3 Select soft good using charts for fluid, pressure and temperature. See selection instructions below.
C) Main Valve Temperature Limits - Refer to Table 2 on page 3900.10. - Locate the material and durometer and verify the temperature limits. - If temperature limits are exceeded, repeat Steps A & B. - If an O-Ring cannot be selected, contact the factory.
D) Pilot Valve Pressure and Temperature Limits - Refer to Table 3 on page 3900.10. - Locate the service and review the pressure and temperature ranges,
then select the material and durometer.
3900 MPV™
O-Ring Materials
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.10
NOTES: 1 Disc O-Ring will be of the same material and durometer as that selected for the Seat O-Ring. 2 Maximum set pressure for silicone compounds is half of the maximum value. 3 When Teflon® material is selected for the Seat O-Ring a Teflon® energized seal will be provided for the Disc Seal.
Table 1 - Main Valve Pressure Limits (psig)1
Pressure and Temperature LimitsMain Valve and Pilot Valve/Modulator
Table 3 - Pilot Valve and Modulator Pressure/Temperature Limits
NOTES: 1 Consult factory concerning the use of Kalrez®. 2 Other materials are on application. Consult factory for availability of other materials. 3 Standard O-Ring Material
The CONSOLIDATED MPV™ (Modular Pilot Valve) Pilot Operated Safety Relief Valve is offered as both a non-flowing pop pilot and a non-flowing modulating pilot within a single assembly. The unique modular design construction allows for an open yoke or vented bonnet and easy field conversion from one configuration to the other. The pilot valve operates by sensing system pressure and using this pressure to control the closing force on the main valve disc. Increasing inlet valve pressure results in increased closing force until the pilot valve opens. Pressure is relieved at a designated set point as process media is allowed to discharge through the main valve. Use of the pop pilot configuration will result in a main valve disc “pop” action from the seated position to 100% open. When the overpressure condition is relieved, the main valve disc will reseat due to the increased media pressure directed through the pilot valve to the top of the valve disc (dome).
Pop Pilot (PV) -Operating Principles and Performance
Pilot Tightness: 98% of set pointBlowdown: 2% to 5%, or 2psi (whichever is greater) depending
upon ramp rate.Longer Blowdown Results from: Fast ramp up increasing the set point or fast ramp down
decreasing the reseat point.Shorter Blowdown Results from: Slow ramp up or slow ramp down.Pilot Tightness after Main Valve Pop: 95% of set pointPilot Tightness after Pilot Reseats: 98% of set pointVent to Main Valve Outlet if: Back Pressure is constant or no back pressure
Pop Pilot Performance
Pressure Ranges: 15 psig - 3750 psig (liquid or gas) 15 psig - 750 psig (steam)Temperature Range: -40°F to 505°F
Compatible for liquid, gas, or steam service
Common Characteristics
3900 MPV™
Pop Pilot Product Operation
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.12
Pop Pilot Operation
PV Valve Open (Relieving Position)
Return to Normal Position
When the discharging main valve reduces the inlet pressure to the preset blowdown pressure of the pilot, the pilot piston closes the vent seal. Simultaneously, the inlet seal is reopened in the pilot. The main valve inlet pressure is again allowed to enter the dome above the main valve disc. As the dome pressure equalizes with the inlet pressure, the downward force created by the differential areas of the disc closes the main valve.
Discharge Through Main Valve
The main valve disc is allowed to lift off the seat as the fluid force overcomes the now removed pressure load above the main valve disc. The valve discharges to relieve system pressure.
As inlet pressure increases, the pilot piston strokes and seals off the main valve inlet pressure from the dome pressure. The pilot simultaneously opens the vent seal to relieve the dome pressure to atmospheric pressure.
Domearea
System pressure from the main valve inlet is fed to the dome area by the pilot through interconnecting tubing. This equalizes the pressure on the top of the disc with inlet pressure on the seating surface (bottom) of the disc. Since the area of the top of the disc is larger than the area of the seating surface, the differential area results in a net downward force keeping the main valve tightly closed.
PV Valve Closed (Normal Position)
3900 MPV™
Pop Pilot Materials (PV)
3900 (SRV-1/Q2.02)3900.13
3900 Series Type 39PV Pilot Pop Action, Non-FlowingFor Set Pressures 15 psig to 3750 psig
NOTE: 1 Pilot valves are available in materials other than those shown above. Refer to the 2900 section of this catalog for alternate materials of construction.
3900 MPV™
Pop Pilot Materials (PV)
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.14
The CONSOLIDATED 39PV pop action non-flowing pilot provides excellent performance with full lift at set pressure with minimal blowdown. Buna N O-Rings and 316 stainless steel construction throughout are standard.The pilot is non-flowing at full open, improving its capabilities to handle dirty conditions and reduce icing problems. There are two unique features of the 39PV. It has the ability to be used on liquid, gas or steam service without any adjustments. The 39PV pop action pilot may be converted to
the 39MV modulating pilot by simply installing the Modulator Assembly. This simple, modular design allows for easier maintenance and fewer spare parts.Set pressures are field adjustable, and testing is easily performed using the standard field test connection. Manual blowdown, sensing line filter, backflow preventer, and remote sensing are available as options.
Description
BONNET OPTION
47
50
9
482625
49
12
20
13
6
7
19
9
12
24
20
23
8
18
5
4
14
2
10
17
3
21115
11
22
16
36
HIGH PRESSURE
3900 (SRV-1/Q2.02)3900.15
The CONSOLIDATED MPV (Modular Pilot Valve) Pilot Operated Safety Relief Valve is also offered as a non-flowing modulating pilot design, using a unique modular configuration which allows for easy field conversion from pop operation to modulating operation. The modulating pilot operation is very similar to the pop pilot operation with the added ability to hold a percentage of system pressure above the main valve disc, producing a modulating action. Increasing system pressure results in reduced closing force due to venting through the pilot valve. Pressure relief begins at a designated set point as process media is discharged through the main valve. However, the actual lift of the main valve disc is based on the specific system overpressure condition instead of “popping” instantaneously to the 100% open position as with the pop pilot. This “modulating” action results in improved operating efficiencies through reduced media loss and lower emissions.
Modulating Pilot (MV) -Operating Principles and Performance
Pilot Tightness: 99% of set point
Blowdown: 1% to 4%, or 2 psi (whichever is greater) depending upon ramp rate.
Pilot Tightness after Pop: 96% of set point
Pilot Tightness after Reseat: 99% of set point
Note: Tightness is defined as zero bubbles per minute.
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.16
Modulating Pilot Operation
Domearea
Modulating Position
As inlet pressure increases, the pilot piston strokes and seals off the main valve inlet pressure from the dome pressure. The pilot simultaneously opens the vent seal to relieve the dome pressure to the bottom of the modulator piston. The modulator piston has a differential area with the smaller area being on top. The top of this piston always sees the main valve inlet pressure. When the dome pressure is applied to the bottom of the modulator piston, there is a net upward force. This is due to both pressures being equal (at this point), and the lower area is larger than the upper area. The modulator relieves pressure from the dome to the atmosphere until force from the inlet pressure on top of the modulator piston is sufficient to move it to the closed position. A certain amount of pressure remains in the dome. This pressure is controlled by the differential area in the modulator. Since the dome pressure has not been dropped to atmospheric pressure, the main valve only partially opens at the set point. The modulator piston will remain closed until the main valve disc is forced into higher lift by increasing inlet pressure. As this occurs, the modulator piston may relieve further pressure from the dome as necessary to achieve the required main disc lift within 10% overpressure.
MV Fully Open
As the inlet pressure increases further, the net upward force on the main valve increases, allowing the main valve to relieve more pressure. The disc obtains full lift (full capacity) within 10% of set pressure.
Return to Normal Position
When the discharging valve reduces the inlet pressure to the pre-set blowdown pressure of the pilot, the pilot piston closes the vent seal. Simultaneously, the inlet seal is reopened in the pilot. The main valve inlet pressure is again allowed to enter the dome above the main valve disc. As the dome pressure equalizes with the inlet pressure, the downward force created by the differential areas of the disc closes the main valve.
System pressure from the main valve inlet is fed to the dome area by the pilot through interconnecting tubing. This equalizes the pressure on the top of the disc with inlet pressure on the seating surface (bottom) of the disc. Since the area of the top of the disc is larger than the area of the seating surface, the differential area results in a net downward force keeping the main valve tightly closed.
MV Valve Closed (Normal Position)
3900 MPV™Modulating Pilot Product Operation
3900 (SRV-1/Q2.02)3900.17
3900 Series Type 39MV PilotModulating Action, Non-FlowingFor Set Pressures 15 psig to 3750 psig
Insert TopInsert BottomMain PistonCompression Screw CapYoke Cap ScrewAdjuster Bottom O-RingAdjuster Top O-RingInsert O-RingMain Base O-RingYokeMain Piston Spring SealAdjuster Top Spring SealInsert Spring SealField Test Connector - Ball - Seat O-Ring - Plug O-Ring - Base - Plug - Tube FilterVent Assembly / Bug Screen - Male Elbow - ScreenModulator BaseModulator StopModulator Piston TopModulator Piston BottomO-Ring RetainerRetainer Lock ScrewModulator Cap ScrewSocket Head Cap ScrewModulator Base O-RingModulator Stop O-RingModulator Seat O-RingModulator Piston Bottom O-RingPiston Bottom Spring SealPiston Top Spring SealSpring CoverVent Assembly - Male Elbow - ScreenTop PlateSet ScrewBonnet
NOTE: 1 Pilot valves are available in materials other than those shown above. Refer to the 2900 section of this catalog for alternate materials of construction.
3900 MPV™Modulating Pilot Product Operation
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.18
The CONSOLIDATED 39MV Pilot Operated Safety Relief Valve is a non-flowing modulating pilot valve that provides exceptional performance and stable operation. The 39MV design controls the attached main valve so as to relieve only enough system pressure to control the system upset, thereby minimizing the media lost. This patented technology is the latest advancement in pilot design within the pressure range of 15 psig to 3750 psig for vapor, liquid and steam service. The 39MV design is the only non-flowing modulating valve of its kind available with adjustable blowdown.This unique modulator is a simple addition to the 39PV pop action design. The simplicity of design allows for easier maintenance and for lower spare parts inventory.
Manual Blowdown ValveAn optional manual blowdown valve is available for relieving the pilot operated safety relief valve. Consult factory for applications requiring a pneumatic or electrical solenoid blowdown valve which may be connected to a distant location, such as an operator station, for remote actuation. The blowdown valve is ported directly to the main dome area, so that the media in the dome is vented when the blowdown valve is actuated, thus allowing the main valve to open.For all applications on air, water over 140°F, or steam service, ASME Section VIII - Division 1 requires each pressure relief valve to have a lifting device such as a blowdown valve or a means of connecting or applying pressure to the pilot to verify that the moving parts essential to good operation are free to move. (Reference UG 136(a)(3)).The lifting lever or blowdown valve may be omitted under Code Case 2203. All orders for pressure relief valves without levers or blowdown valves for steam, air and water over 140°F must state specifically that the valves are being purchased per Code Case 2203. The purchaser is responsible for obtaining jurisdictional authorization for use of Code Case 2203.
Field Test ConnectionA 1/4” FNPT field test connection is standard on all pilot valve types. This allows the stroking of the valve with an auxiliary media, e.g. air or nitrogen. An internal check valve is present in the field test connection isolating the inlet media from the test media and at the same time, allowing the valve to open normally in the event of a system overpressurization during a field test.
FiltersFilter options are available for dirty applications. These filters are installed in the pilot inlet sensing line.For the 39PV and 39MV, an optional sensing line filter is available. This filter has a 316 stainless steel body, Teflon® seals, and a 40-50 micron stainless steel filter element. This filter is standard for steam service.Other high capacity filter options include: (1) a carbon steel cadmium coated filter body with a 35 micron stainless steelelement, (2) a stainless steel filter body, and (3) an entirely stainless steel filter arrangement. The O-Ring in the filters for steam service will be Teflon®. These filters may be equipped with a manually operated needle valve which allows for purging the filtered material while the valve is in operation.All filter elements are stainless steel, and all filters, including carbon steel, conform to NACE Standard MR0175.A dual filter arrangement is available for applications in which the customer is unsure of the filter maintenance requirements. In these cases, a preventive maintenance program may be developed by monitoring the filters, without taking the valve off line.
Backflow PreventerWhen the pilot operated safety relief valve is not vented directly to atmosphere, it is possible to build up back pressure in the discharge line. This is typical in situations where several valves manifold into a common discharge header. Should the discharge line pressure exceed the valve inlet pressure, it could cause the piston to lift and allow reverse flow through the main valve. This situation can be eliminated through the use of the Backflow Preventer.
3900 MPV™
Pilot Design Options
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.20
Spring CoverAn optional metal spring cover that fits over the yoke arms.
BonnetA vented Bonnet that replaces the Yoke provides protection of personnel. The bonnet will protect the spring from external debris and weather conditions (See page 3900.14 or 3900.18).
Pressure Differential SwitchElectrical: A pressure differential switch is available which may be wired to an operator station or some other remote location. The switch will provide a signal that indicates when the main valve is opening. The standard pressure differential switch is a single pole, double throw, rate at 5 amps and 30 volts DC with a NEMA 4 enclosure. (For other configurations, consult the factory.)Pneumatic: For applications that do not permit an electrical differential switch, an option is available to provide pneumatic signal to indicate when the main valve opens.
Remote Pilot MountingThe 39PV and 39MV pilots can be mounted separately from the main valve. Remote pilot mounting will allow heating or cooling the pilot in case ambient conditions are outside the scope of the pilot. It will also enable the user to group several pilots together for control of ambient conditions in a smaller space. In addition, this promotes easier maintenance.
Dual PilotsA dual pilot arrangement is available for applications in which the pilot valve O-Rings require monitoring and/or maintenance more often than the main valve. In this installation, the pilot valves may be alternated for maintenance, without bringing the system down.
NOTE: For all option and accessory material variations, contact the factory.
Remote SensingThe pilot valve inlet may be piped to a location remote from the main valve. In this application, the customer may pipe the inlet sensing line to some location other than where the main valve is located and where the pressure will be relieved (for tubing size and maximum length, consult factory for recommendations.)
Pilot Valve TesterThe pilot valve test indicator is available for the modulating and pop action pilot valves. The valve test indicator measures the set pressure of the pilot, while maintaining pressure on the main valve dome area; thereby, allowing only the pilot to actuate. The system shown below is available for remote or local testing.
Spring Cover (optional)
3900 MPV™
Pilot Design Options
3900 (SRV-1/Q2.02)3900.21
Dirty Service Option
MPV Dirty Service Pilot
Process media controls the set pressure & blowdown.
Clean media supplypiped to pilot.
Severe dirty service, precipitation and viscous fluid problems can be solved using the dirty service option offered on the 3900 POSRV. A dirty service option can be added to the standard pilot valve. The kit contains a 316 SS chamber, an isolation seal and an extended pilot piston. The module is positioned at the top of the pilot valve body and below the pilot valve yoke. Crucial valve components such as the modulator, dome assembly, vent, and inlet seals never come in contact with the dirty system media. The process media pressure still controls the set pressure and blowdown of the POSRV.For applications requiring the main valve to relieve the dirty fluid, an alternate clean media supply is piped to the pilot. The alternate clean media must be set at the same pressure as the set pressure of the pilot valve, but cannot exceed 3750 psig, which is the design limit of the pilot valve. In the event that the alternate clean media supply is lost, the main valve will fail in the open position.For applications requiring the main valve to relieve clean fluid upstream of the dirty process in order to maintain the dirty process pressure at safe levels, the dirty process pressure is supplied to the dirty service module. The sensing line from the main valve and the connection to the main valve dome is connected to the pilot in the normal manner. The pilot is set to operate at the design pressure of the dirty process. When the dirty process pressure reaches the set to open pressure of the
pilot, the pilot is stroked by the increase in the dirty process pressure and the pilot performs the block and bleed operations to effect opening of the main valve. When the dirty process pressure reaches the set to close pressure of the pilot, the pilot is stroked by the reduction in the dirty process pressure and the pilot performs the block and bleed operations to effect the closing of the main valve.The dirty service module is a closed chamber. The flow of dirty process media to the pilot valve is only that volume required to stroke the pilot in response to increasing dirty process pressure. The limited volume of flowing dirty media entering the pilot makes plugging of the module an unlikely possibility. However, if plugging of the module is a concern, the module can be filled with a compatible clean liquid and a siphon tube can be fitted in the connection line between the pilot module and the dirty process.The dirty service option can provide some cost savings in material selection for corrosive service. It is possible that only the material of construction for the dirty service option will need to be upgraded. The remaining parts in contact with clean media could use standard materials of construction.
NOTE: For special material options on the dirty service option consult the factory.
3900 MPV™
Piping Configurations
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.22
APPROVED: ASME Boiler & Pressure Vessel Code, Section VIII (for set pressure 15 psig and above). CERTIFIED: National Board of Boiler and Pressure Vessel Inspectors.
Air
3900 MPV™
Capacities (USCS)
3900 (SRV-1/Q2.02)3900.57
APPROVED: ASME Boiler & Pressure Vessel Code, Section VIII (for set pressure 15 psig and above). CERTIFIED: National Board of Boiler and Pressure Vessel Inspectors.
Series 3905 - 3916 Type PV & MV PilotsFULL BORE - ORIFICE CAPACITIES - AIR
(USCS Units)
Capacities based on set pressure plus 10%or 3 psi overpressure, whichever is greater.
Capacities in standard cubic feet per minute @ 60°F.
APPROVED: ASME Boiler & Pressure Vessel Code, Section VIII (for set pressure 15 psig and above). CERTIFIED: National Board of Boiler and Pressure Vessel Inspectors.
Water
3900 MPV™
Capacities (USCS)
3900 (SRV-1/Q2.02)3900.59
Series 3905 - 3916 Type PV & MV PilotsFULL BORE - ORIFICE CAPACITIES - WATER
(USCS Units)
Capacities based on set pressure plus 10%or 3 psi overpressure, whichever is greater.
Capacities in gallons of water per minute @ 70° F,and zero psig back pressure.
APPROVED: ASME Boiler & Pressure Vessel Code, Section VIII (for set pressure 15 psig and above). CERTIFIED: National Board of Boiler and Pressure Vessel Inspectors.
Water
3900 MPV™
Capacities (USCS)
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.60
APPROVED: ASME Boiler & Pressure Vessel Code, Section VIII (for set pressure 15 psig and above). CERTIFIED: National Board of Boiler and Pressure Vessel Inspectors.
Steam
3900 MPV™
Capacities (USCS)
3900 (SRV-1/Q2.02)3900.61
Series 3905 - 3916 Type PV & MV PilotsFULL BORE - ORIFICE CAPACITIES - STEAM
(USCS Units)
Capacities based on set pressure plus 10%or 3 psi overpressure, whichever is greater.
APPROVED: ASME Boiler & Pressure Vessel Code, Section VIII (for set pressure 15 psig and above). CERTIFIED: National Board of Boiler and Pressure Vessel Inspectors.
Steam
3900 MPV™
Valve Installation
Consolidated Pilot Operated Safety Relief Valves 3900 (SRV-1/Q2.02)3900.62
Valve ConnectionsThe CONSOLIDATED 39MPV Series flanged valves are equipped with ANSI B16.5 flanges. For other standards, contact the factory for your needs.The facing on raised flanges is a spiral finish, 125 to 250 micro inch roughness (Ra).All flange drilling straddles the centerlines of the valve.
Handling and StorageSafety relief valves should be handled carefully. The internal parts of a pilot operated safety relief valve are precision machined and fitted together to maintain perfect alignment. Rough handling may damage the external tubing, pilot, and main valve seats or may cause misalignment sufficient to incur leakage or erratic operation. Safety relief valves are shipped with a protective covering over the inlet and the outlet. This is to prevent damage to the flanged surfaces and to prevent entry of foreign material into the valve. If the valves are to be stored before installation, the protective covering should be left intact until installation. A clean, dry storage area is recommended. Valves should always be protected with a suitable covering to prevent entry of foreign material.
Inlet PipingPilot operated safety relief valves must be installed in a vertical upright position. The inlet piping to the valve should be short and direct from the vessel or equipment being protected. The connection to the vessel should be provided with a radius to permit smooth flow to the valve. Sharp corners should be avoided. Should this not be practical, then the inlet should be swaged out at least one additional pipe diameter.In any event, the pressure drop from the vessel to the valve should not exceed 3% of set pressure when the valve is flowing full capacity. In no event should the inlet piping be smaller in diameter than the inlet connection of the valve.
Outlet PipingAlignment of the internal parts of a pilot operated safety relief valve is important to ensure proper operation. Although the valve body will withstand a considerable mechanical load, unsupported discharge piping should not impose loads any higher than that stated in the Technical Information section of this catalog, consisting of more than a companion flange, long radius elbow and a short vertical pipe. Care should be taken to ensure thermal expansion of piping and supports does not produce strains on the valve. Spring supports are recommended where necessary to avoid this condition. The discharge piping should be designed to allow for vessel expansion as well as expansion of the discharge pipe itself. This is particularly important on long discharge lines.Consideration should be given to discharge pipe movement resulting from wind loads. Any oscillation of the discharge piping introduces stress distortion in the valve body, and the resultant movement of the internal parts may cause leakage.